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Maintenance

Belt Replacement

and

Pump Drive Belt

Replacement

sections for belt replacement.

Change Gearbox Oil

Service Interval: After the first 50 hours

Every 2,000 hours
thereafter

1. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

2. Place unit on a level surface.

3. Remove the gearbox and drive shaft assembly

from the mower deck. Retain hardware for re-use.

4. Remove the large oil drain plug on the front of

each of the three gearbox sections and drain oil
(Figure 20).

Figure 20

Small magnetic plugs
(front and back)

Small magnetic plug
(front only)

Large oil drain/fill plug

5. Remove small magnetic plugs and wipe away any

material accumulated on the plugs.

6. Apply a Teflon pipe sealant to all small magnetic

plugs and re-install into the gearbox.

7. Re-install the gearbox and drive shaft assembly

to the mower deck.

8. Fill gearbox with Mobil SHC (synthetic) 75W-90

gear lube oil until level with oil drain/fill plug.
Each of the gearbox sections must be filled
separately.

Note:

Mower deck should remain level to the

ground when filling gearbox with oil. Do Not fill
gearbox with deck raised in the service position.

9. Apply a Teflon pipe sealant to the 3 large oil plugs

and re-install into the gearbox.

Check Gearbox Oil

Service Interval: Every 100 hours

1. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

2. Place unit on a level surface.

3. Add oil as needed until level with oil drain plug;

see

Change Gearbox Oil

section.

Lubricate Grease Fittings

Note:

See chart for service intervals.

1. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

2. Lubricate fittings with one to two pumps of

NLGI grade #2 multi-purpose gun grease.

Refer to the Lubrication Chart for fitting locations
and lubrication schedule.

Lubrication Chart

Fitting

Locations

Initial

Pumps

Number of

Places

Service

Interval

1. Caster
Pivot

*Yearly

2. PTO
Idler

Yearly

3. Pump
Idler

Yearly

4. Rear
Caster Hub

*Yearly

5. Drive
Shaft

40 Hours

6. Front
Caster
Wheel Hub

8 Hours

7. Deck
Flip-Up

100 Hours

8. Push
Arm Tubes

100 Hours

9. Front
Caster
Pivots

*Yearly

* See step 3 for special lubrication instructions on
the front and rear caster pivots and the

Lubricate

Rear Caster Wheel Hubs

section for special

lubrication instructions on the rear caster wheel
hubs.

Содержание NAVIGATOR

Страница 1: ...NAVIGATOR For Serial Nos 400 000 000 Higher Part No 4503 256 Rev A ...

Страница 2: ... Engine Service Dealer This spark ignition system complies with the Canadian standard ICES 002 Ce système d allumage par ètincelle de vèhicule est conforme à la norme NMB 002 du Canada Please refer to the engine manufacturer s information included with the machine Labeled power ratings are supplied by the engine manufacturer in accordance with SAE testing and gross net power rating standards J1940...

Страница 3: ...com for additional safe operation information such as safety tips training materials and Operator s manuals If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficien...

Страница 4: ...s 38 Lubricate Hopper Switch Actuator 38 Check Spark Plugs 38 Change Hydraulic System Filter and Fluid 38 Check Wheel Hub Locknuts 39 Check Wheel Lug Nuts 39 Thread Locking Adhesives 39 Dielectric Grease 39 Adjustments 40 Deck Leveling 40 PTO Drive Belt Tension 40 Pump Drive Belt Tension 40 PTO Belt Replacement 40 Pump Drive Belt Replacement 41 Belt Guide Adjustment 41 Adjust Safety Switch 42 Park...

Страница 5: ...n not read this manual it is the owner s responsibility to explain this material to them other languages may be available on our website Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local...

Страница 6: ...lace and in proper working condition DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or ...

Страница 7: ...tarting engine Never raise deck with blades running Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Park machine on level g...

Страница 8: ...re on slopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden st...

Страница 9: ... blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Charging or jump starting the battery may produce explosive gase...

Страница 10: ...r familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safel...

Страница 11: ...rface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower 93 6696 1 Stored energy hazard Remove the spring from the tractor section only See Operator s manual for disassembly procedure 93 7818 1 Warning read the Operator s manual for ins...

Страница 12: ...lding deck hazard Lock the pivot joint by pushing inward and rotating towards the front of the deck 116 8936 1 Danger Do Not operate with deck in tilt up position 116 8941 116 8943 1 Rotating blades hazard Disengage PTO move speed control lever in neutral engage parking brake stop engine and remove key before leaving the operator s position Read the instructions before servicing or performing main...

Страница 13: ...r performing maintenance 116 9049 1 Rotating driveline hazard Keep all drivelines shields in place Securely attach both ends of the driveline 116 9357 EFI Units 1 Neutral 4 Slow 2 Reverse 5 Hopper down 3 Fast 6 Hopper up 116 9375 All Units Except EFI 1 Neutral 3 Fast 2 Reverse 4 Slow 116 9470 All Units Except EFI 1 Choke on 2 Choke off 117 2718 13 ...

Страница 14: ...tion must be in hatched area or adjustment is required 126 7425 EFI Units 1 Fast 4 Neutral 2 Machine speed 5 Engine oil temperature light 3 Slow 6 Check engine 126 7442 All Units Except EFI 1 Fast 4 Neutral 2 Machine speed 5 Engine oil temperature light 3 Slow Molded in LH Console 1 PTO disengage 3 Park brake release 2 PTO engage 4 Park brake engage 14 ...

Страница 15: ...s every 100 hours 3 Grease front caster wheel bearings every 8 hours 10 Check gearbox oil every 100 hours use only Mobil 1 75W 90 gear oil 4 Check hydraulic oil level every 40 hours only use recommended hydro oil 11 Grease front caster pivots every 500 hours 5 Check tire pressure every 40 hours 12 Grease rear caster pivot every 500 hours 6 Grease deck drive PTO every 40 hours 13 Grease rear caster...

Страница 16: ...wly when turning 6 Warning Disengage PTO move speed control lever to neutral position engage parking brake and stop engine before leaving the operator s position 3 Warning Do Not use dual ramps use one piece ramps when transporting machine Do Not use ramps with inclination greater than 15 degrees 7 Thrown object hazard Pick up objects that could be thrown by mower Do Not operate when people and pe...

Страница 17: ...e RH control panel PTO must be disengaged brake engaged and speed control lever in neutral to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or speed control lever is moved out of neutral or engine will stop Engine will stop if the hopper is raised while the PTO is engaged Operator Controls St...

Страница 18: ...48 inch Deck 25 00 inches 63 5 cm Deck Drive Clutching belt on horizontal engine shaft Dual A section hexagon belt with spring tensioned idler to jackshaft and blower Heavy duty cast iron spiral bevel gearbox is final drive to blades Gearbox Oil Type Mobil SHC synthetic 75W 90 gear lube Deck Full floating deck is attached to out front support frame Deck design allows for bagging or mulching Deck D...

Страница 19: ...ts Bolt Location Torque Blade Mounting Bolt 85 110 ft lb 115 149 N m Engine Mounting Bolts 30 35 ft lb 41 47 N m Wheel Lug Nuts 85 105 ft lb 122 129 N m Wheel Motor Mounting Bolts 72 77 ft lb 115 142 N m Wheel Hub Locknut 275 350 ft lb 373 475 N m Blade Driver Shear Bolts 80 100 in lb 922 1130 N cm Product Overview Figure 4 1 Speed Control Lever 4 Steering Levers 2 Controls 5 PTO Engagement Lever ...

Страница 20: ...rol is pulled out to be in the ON position and pushed in to be in the OFF position Do Not run a warm engine with choke in the ON position Figure 5 1 Ignition switch 5 Throttle 2 Hopper switch 6 Engine oil temperature light and buzzer 3 Message display 7 Check engine light EFI Units Only 4 Choke All Units Except EFI Throttle Control Located on right hand console The throttle is used to control engi...

Страница 21: ...se drive system Turn clockwise to reset system Do Not overtighten Do Not tow machine Tracking Adjustment Knob Located under the seat on the left pump control link Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position Run unit at 3 4 speed for at least 5 minutes to bring hydraulic oil up to operating temperature Stop...

Страница 22: ... engine push the choke lever forward into the ON position except Kohler EFI On a warm engine leave the choke in the OFF position 6 Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failu...

Страница 23: ...s back toward neutral in the direction desired The machine will move faster the farther the speed control lever is moved away from neutral 4 To stop pull the speed control lever back to the neutral position Driving in Reverse 1 To move rearward in a straight line applying equal pressure pull both steering levers rearward To turn left or right release pressure on the steering lever toward the direc...

Страница 24: ...r deck to ground see Figure 8 2 Push deck locking pins inward and rotate forward to securely lock deck in lowered position see Figure 7 WARNING Operating mower without locking pins securely latched can result in the mower deck folding up unexpectedly The mower deck folding up unexpectedly can cause serious injury Always operate mower with locking pins securely latched Adjusting Fill Reduction Syst...

Страница 25: ... Remove bolt and washer at the front of each of the FRS baffles Rotate baffles into desired position and reinstall bolt and washer Figure 11 1 Baffles shown in closed position 2 Baffles shown in open position 3 Bolt 4 Washer 5 Baffles 6 Lower deck per Lowering the Mower Deck to the Operating Position section 7 Snug nyloc nuts on the rear studs of the FRS baffles These nuts may be left slightly loo...

Страница 26: ...or without an approved Exmark front mount attachment 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise mower deck up and latch with deck locking pins per Raising the Mower Deck to the Service Position section in Operation 3 Remove hairpins and washers at the top of the deck lift assist spring on each side of the unit see Figure 12 Figure 12 1 Spring anchor...

Страница 27: ... and remove key Engage parking brake 2 Roll the mower deck up to the Navigator tractor with the discharge tube down making sure the deck springs are located above the drive wheel and below the console on each side 3 Raise seat and install drive shaft onto jackshaft see Figure 15 4 Align deck push arm tubes to tractor push arms and push deck rearward Secure push arms with lynch pins on left and rig...

Страница 28: ...ded Excessive build up on the screen can cause the blower to plug Note In conditions where the screen clogs quickly the front removable screen panel can be turned and reinstalled under the primary screen to allow free air flow from the hopper Figure 16 1 Front removable screen can be rotated and stored for wet conditions 3 Primary screen 2 Front removable screen 4 Handles Transporting Transporting...

Страница 29: ...ll width ramp is required If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angle...

Страница 30: ...cknuts torque specification Check the wheel lug nut torque specification Before each use or daily Check the engine oil level Check the mower blades Check the safety interlock system Check for loose hardware Grease the front caster wheel hub Remove accumulated debris from engine see Cleaning section Clean the grass and debris build up from the machine Clean the grass and debris build up from the cu...

Страница 31: ...k on the dipstick or over the FULL mark Check Battery Charge Service Interval As required WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging the...

Страница 32: ...pen shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist 2 Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the cor...

Страница 33: ...e a block of wood or locking pliers to hold blade in place and remove the 1 2 20 x 2 1 4 inch blade bolt that secures the blade and blade driver 5 Re install the blade driver with new blades by using a block of wood or locking pliers to hold the blade in place and torque the blade bolts to 85 110 ft lb 115 149 N m Note Blade driver flats must be aligned with the flats on the shaft when installing ...

Страница 34: ...move key Engage parking brake 2 Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service Air Cleaner Service Interval Every 50 hours Service the air cleaner May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remo...

Страница 35: ...ervoir cap and remove cap 5 Wipe the dipstick clean and re insert the cap back into the hydro Lightly tighten the cap 6 Remove the cap again and check the level of the oil on the dipstick See Figure 19 for oil levels Figure 19 1 Full 2 Add Note The oil level on the dipstick will be incorrect if the oil is checked when the unit is hot 7 If the dipstick oil level does not register on the dipstick ad...

Страница 36: ...arbox with oil Do Not fill gearbox with deck raised in the service position 9 Apply a Teflon pipe sealant to the 3 large oil plugs and re install into the gearbox Check Gearbox Oil Service Interval Every 100 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Place unit on a level surface 3 Add oil as needed until level with oil drain plug see Change Gearbox...

Страница 37: ...nuts removed or broken loose apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do Not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with ...

Страница 38: ...bricate each end of both steering linkage rods with a spray lubricant or a light oil Lubricate Hopper Switch Actuator Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise hopper and locate actuator on right hand side of mainframe 3 Lubricate switch actuator rod with a spray lubricant or a light oil Check Spark Plugs Service In...

Страница 39: ...il except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Check Wheel Hub Locknuts Service Interval After the first 100 hours Every 500 hours thereafter Torque to 275 350 ft lb 373 475 N m Check Wheel Lug Nuts Service Interval After...

Страница 40: ...ive Belt Tension Self tensioning No adjustment necessary PTO Belt Replacement 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 With engine off engage PTO lever then remove the hairpin and clevis pin at the bottom of the PTO brake band 3 Rotate the brake band upwards out of the way of the belts keeping clear of the belt drive 4 Disengage PTO lever 5 Loosen belt ...

Страница 41: ...for removal instructions 3 Pull spring idler or remove spring to relieve pump drive belt tension Remove old belt 4 Route new belt onto sheaves as shown in the decal located on the back of the left drive shield see Figure 26 Figure 26 1 Pump Drive Belt 4 Pump 2 Pump 5 Idler 3 Idler 6 Engine 5 Reinstall PTO Belts as stated in the PTO Belt Replacement section Belt Guide Adjustment 1 Stop engine wait ...

Страница 42: ...g brake 3 Unhook the seat latch and tip the seat forward 4 There should be no slack between the park brake handle and the linkage If an adjustment is necessary remove the clevis pin and rotate the linkage counterclockwise to lengthen or clockwise to shorten Figure 29 1 Parking brake 4 Speed control lever 2 Rotate yoke 5 Steering levers 3 Clevis pin 5 Measure the compressed spring length on both ve...

Страница 43: ...e play in the brake linkage with no dragging in the brakes Reverse Stop Rod Adjustment 1 Stop engine wait for all moving parts to stop and remove key 2 Engage the parking brake and check the movement of the steering levers If the levers move slightly forward up to 1 8 inch 3 mm then no adjustment is necessary If the levers do not move then proceed with the following steps A Flip up the seat or rem...

Страница 44: ...riction bracket 3 Speed control friction plate 6 Speed control lever 3 Set the tension high enough that the speed control lever position is maintained during operation and loose enough to be moved comfortably by the operator Speed Control Linkage Adjustment WARNING Engine must be running and drive wheels must be turning so motion control adjustment can be performed Contact with moving parts or hot...

Страница 45: ...light pressure to the levers allow the steering levers to return to neutral The wheels must stop turning or slightly creep in reverse 9 Stop engine and wait for all moving parts to stop Remove jumper wire from wire harness connector and plug connector into seat switch 10 Lower from jackstands Tracking Adjustment See Motion Control Linkage Adjustment section PTO Drive Pulley Alignment PTO drive pul...

Страница 46: ...ne has been moved or replaced The pump pulleys have been loosened moved or replaced The PTO pulley alignment has been performed see PTO Drive Pulley Alignment section 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Loosen set screws on both pump pulleys 3 Using a straight edge align each pump pulley with the engine pulley by sliding along the pump shaft see Fi...

Страница 47: ...parts to stop and remove key Engage parking brake 2 Locate the brake spring and thread the two jam nuts out to the end of the brake spring rod see Figure 39 3 Tighten jam nuts together at end of brake spring rod Figure 39 1 Tighten jam nuts here 2 PTO Brake spring assembly Deck Locking Pin Stop Adjustment 1 Slide deck locking pins in on both sides and rotate to lock the deck in the operation posit...

Страница 48: ...s Swing out the fuel tank and remove debris from around the oil cooler positioned at right front corner of engine Important Do Not use water to clean engine Use low pressure compressed air See Engine Owner s Manual Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean off any oil debris or gra...

Страница 49: ...o Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local c...

Страница 50: ...aler 1 Fuel tank is empty 1 Fill the fuel tank 2 Oil level in the crankcase is low 2 Add oil to the crankcase 3 The throttle and choke are not in the correct position 3 Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine except Kohler EFI or the OFF position for a warm engine 4 Dirt in fuel filter 4 Replace the fuel filte...

Страница 51: ...loose 2 Tighten the blade mounting bolt 3 Engine mounting bolts are loose 3 Tighten the engine mounting bolts 4 Loose engine pulley idler pulley or blade pulley 4 Tighten the appropriate pulley 5 Engine pulley is damaged 5 Contact an Authorized Service Dealer 6 Blade spindle is bent 6 Contact an Authorized Service Dealer Abnormal vibration 7 Belt is damaged 7 Install new belt 1 Blade s not sharp 1...

Страница 52: ...Schematics Schematics Electrical Diagram All Units Except Kohler EFI 52 ...

Страница 53: ...Schematics Electrical Diagram Kohler EFI 53 ...

Страница 54: ...Schematics Electrical Schematic All Units Except Kohler EFI 54 ...

Страница 55: ...Schematics Electrical Schematic Kohler EFI 55 ...

Страница 56: ...Schematics Hydraulic Diagram 56 ...

Страница 57: ...u access our website at www exmark com U S or Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warr...

Страница 58: ...58 ...

Страница 59: ...se the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 59 ...

Страница 60: ... RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Some accessories and options not available for some models Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Be...

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